Bonding and slitting device

ABSTRACT

A bonding and slitting device is adapted to form fin seams in absorbent articles having a front waist region, a back waist region, and a crotch region extending between the front waist region and the back waist region. The device includes a first bonding member and a second bonding member having a contact element configured to cooperate with the first bonding member to bond the front region of the chassis to the back region to define the fin seams. A slitter is configured to simultaneously act on material outboard of the bonds from both the front and back regions of the chassis.

CROSS REFERENCE TO RELATED APPLICATION

This application is a divisional application of U.S. patent applicationSer. No. 14/091,829 entitled METHOD OF MANUFACTURING AN ABSORBENTARTICLE HAVING A FIN SEAM, filed Nov. 27, 2013, the disclosure of whichis fully incorporated herein by reference.

FIELD

The present invention relates generally to methods of manufacturingabsorbent articles, and more particularly to methods of manufacturingabsorbent articles having fin seams.

BACKGROUND

Exemplary absorbent articles include training pants, diapers,incontinence products, disposable underwear, medical garments, absorbentswim wear, and the like. Training pants (albeit, not exclusively) aredisposable absorbent articles configured for use in the toilet trainingprocess. Toilet training is a process that includes many trainingtechniques and aids that can be used by parents or other caregivers. Oneaspect of the total toilet training process is changing from the use ofdiapers to the use of training pants to help the child understand thathe or she should now use the toilet.

Many caregivers underestimate the difficulty of teaching the toilettraining process to young children. If a child does not respond to aninitial toilet training instruction or introduction, the caregiver canbe at a loss for finding techniques, methods, or teaching tools toencourage the child to master the art of toilet training. Thus, whilevarious teaching tools such as books, videotapes, charts with stickers,personalized toilets, and interactive toilet training kits areavailable, there remains a need for improved motivational mechanisms tofacilitate the toilet training process.

One motivational mechanism is the use of training pants having animproved aesthetic appearance. Specifically, a child is encouraged towear a garment that resembles underwear worn by older children. Thus,there is an ongoing need to increase the appeal of the toilet trainingprocess to children, and to improve the aesthetic appearance of trainingpants. However, it is important that any modifications to the trainingpants to meet these needs do not compromise the use of the articles orany functional features of the articles (e.g., wetness indicators,absorbency, leakage protection, etc.).

Accordingly, there is a need for a training pant having an aestheticappearance similar to conventional underwear.

SUMMARY

In one aspect, a method for manufacturing absorbent articles isdisclosed. Each of the absorbent articles comprises a chassis and anabsorbent structure disposed on the chassis. The chassis has a frontwaist region, a back waist region, and a crotch region extending betweenthe front waist region and the back waist region. The method generallycomprises folding each of the absorbent articles about a fold linegenerally bisecting the article such that the front and back waistregions are positioned in facing relationship, and simultaneouslybonding and one of trimming and weakening the front and back waistregions adjacent each opposing side edge of the article to form a pairof fin seams.

In another aspect, a method for manufacturing absorbent articles isdisclosed. Each of the absorbent articles comprises a chassis and anabsorbent structure disposed on the chassis. The chassis has a frontwaist region, a back waist region, and a crotch region extending betweenthe front waist region and the back waist region. The chassis defines awaist opening and a pair of leg openings. A waist elastic member isadapted to extend around at least a portion of the waist opening and apair of leg elastic members is adapted to extend around at least aportion of respective ones of the pair of leg openings. The methodgenerally comprises folding each of the absorbent articles about a foldline generally bisecting the article such that the front and back waistregions are positioned in facing relationship, and simultaneouslybonding and one of trimming and weakening the front and back waistregions adjacent each opposing side edge of the article to form a pairof fin seams such that at least a portion of one of the waist elasticmember and the leg elastic members defines part of each of the finseams.

In yet another aspect, a bonding and slitting device is adapted to formfin seams in absorbent articles. The absorbent articles have a frontwaist region, a back waist region, and a crotch region extending betweenthe front waist region and the back waist region. The device generallycomprises a first bonding member and a second bonding member having acontact element configured to cooperate with the first bonding member tobond the front region of the chassis to the back region to define thefin seams and a slitter configured to simultaneously act on materialoutboard of the bonds from both the front and back regions of thechassis.

Other features of the invention will be in part apparent and in partpointed out hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side perspective of one suitable embodiment of an absorbentarticle shown in the form of a training pant, the training pant havingbonded fin seams formed along the sides of the training pant.

FIG. 2 is a bottom plan view of the training pant of FIG. 1 with thetraining pant in an unbonded, unfolded and laid flat condition, andshowing a surface of the training pant adapted to face away from thewearer during use.

FIG. 3 is a top plan view similar to FIG. 2 but showing a surface of thetraining pant adapted to face the wearer during use, portions of thetraining pant being cut away to show underlying features.

FIG. 4 is an enlarged side perspective view of one of the fin seams ofthe training pant of FIG. 1.

FIG. 5 is a cross-section taken along line 5-5 of FIG. 4.

FIG. 6 is a cross-section taken along line 6-6 of FIG. 4.

FIG. 7 is a cross-section taken along line 7-7 of FIG. 4.

FIG. 8 is a schematic illustrating one suitable method for bonding thefin seams of the absorbent article illustrated in FIGS. 1-7.

FIG. 9 is a perspective view of one embodiment of a bonding and slittingdevice suitable for use in the method illustrated in FIG. 8.

FIG. 10A is an enlarged perspective view taken from FIG. 9 andillustrating one suitable bonding pattern.

FIG. 10B is an enlarged perspective view similar to FIG. 10A butillustrating another suitable bonding pattern.

FIG. 11 is another perspective view of the bonding and slitting deviceof FIG. 9.

Corresponding reference characters indicate corresponding partsthroughout the several views of the drawings.

DETAILED DESCRIPTION

Referring now to the drawings and in particular to FIG. 1, one suitableembodiment of an absorbent article is illustrated in the form of achild's toilet training pant and is indicated in its entirety by thereference numeral 20. The term absorbent article generally refers toarticles that may be placed against or in proximity to a body of awearer to absorb and/or retain various exudates from the body. Theabsorbent training pant 20 may or may not be disposable. Disposablerefers to articles that are intended to be discarded after a limitedperiod of use instead of being laundered or otherwise conditioned forreuse. It is understood that the embodiments of the present disclosureare suitable for use with various other absorbent articles intended forpersonal wear, including but not limited to diapers, swim diapers,feminine hygiene products (e.g., sanitary napkins), incontinenceproducts, medical garments, surgical pads and bandages, other personalcare or health care garments, and the like without departing from thescope of the present disclosure.

By way of illustration only, various materials and methods forconstructing training pant such as the pant 20 of the present disclosureare disclosed in U.S. patent application Ser. No. 14/062,278 filedOctober 24, 2013 by Ruman et al.; U.S. patent application Ser. No.14/068,918 filed Oct. 31, 2013 by Sina et al.; U.S. patent applicationSer. No. 14/068,913 filed Oct. 31, 2013 by Bennett et al.; PCT PatentApplication WO 00/37009 published Jun. 29, 2000 by A. Fletcher et al;U.S. Pat. No. 4,940,464 issued Jul. 10, 1990 to Van Gompel et al.; U.S.Pat. No. 5,766,389 issued Jun. 16, 1998 to Brandon et al., and U.S. Pat.No. 6,645,190 issued Nov. 11, 2003 to Olson et al., which areincorporated herein by reference.

As seen in FIGS. 1-3, the training pant 20 has a front waist region 22,a back waist region 24, and a crotch region 26 disposed longitudinallybetween and interconnecting the front and back waist regions. The frontwaist region 22, the back waist region 24 and the crotch region 26 areindicated generally by the respective reference numbers. The trainingpant 20 also has a pair of laterally opposite side edges 28 and a pairof longitudinally opposite waist edges, respectively designated frontwaist edge 30 and back waist edge 32. The front waist region 22 iscontiguous with the front waist edge 30, and the back waist region 24 iscontiguous with the back waist edge 32.

With reference to FIGS. 2 and 3, the training pant 20 includes achassis, indicated generally at 34, and an absorbent assembly, indicatedgenerally at 36, attached to the chassis 34. Arrows 60 and 62 in FIGS. 2and 3 depict the orientation of a longitudinal axis and a transverse orlateral axis, respectively, of the training pant 20. The illustratedabsorbent assembly 36 extends longitudinally from the front waist region22 through the crotch region 26 to the back waist region 24. While theillustrated absorbent assembly 36 is shown and described herein asextending from the crotch region 26 into both the front and back waistregions 22 and 24, it is contemplated that the absorbent assembly 36 mayextend from the crotch region 26 into primarily the front waist region22, or into primarily the back waist region 24, without departing fromsome aspects of this disclosure. Further, the absorbent assembly 36 mayextend any suitable length along the crotch region 26 and/or into thefront waist region 22 and/or the back waist region 24. In theillustrated embodiment, the chassis 34 and the absorbent assembly 36 areformed separately from one another. It is contemplated, however, thatthe chassis 34 and the absorbent assembly 36 may be integrally formedwith one another in some embodiments. It is further contemplated that insome suitable embodiments the absorbent assembly 36 can be disposableand the chassis 34 can be non-disposable.

As seen in FIG. 2, the chassis 34 includes a longitudinally extendingcentral portion 38, a pair of laterally opposite front side portions 40extending outward from the central portion 38 at the front waist region22 (thereby forming transversely outer portions of the front waistregion, and more broadly in part forming transversely opposite sides ofthe training pant), and a pair of laterally opposite back side portions42 extending outward from the central portion at the back waist region24 (thereby forming transversely outer portions of the back waistregion, and together with the front side portions 40 further definingthe sides of the pant). In the illustrated embodiment, the centralportion 38 extends from the front waist region 22 through the crotchregion 26 to the back waist region 24 of the training pant 20.

In one suitable embodiment and as seen in FIG. 2, the front sideportions 40, the back side portions 42, and the central portion 38 areformed from the same sheet of material. In other suitable embodiments,one or more of the front side portions 40, the back side portions 42,and/or the central portion 38 may be formed from two or more separateelements. For example, in one suitable embodiment, the front sideportions 40 and/or the back side portions 42 can be formed separatelyfrom and attached to the central portion 38.

The chassis 34 may comprise any suitable material including, for exampleand without limitation, a liquid permeable material that provides agenerally cloth-like texture. The chassis 34 can be a single layer ofmaterial, or a multi-layered laminate structure. The chassis 34 orportions thereof may also be made of those materials of which the liquidpermeable bodyside liner 48 is made. In other suitable embodiments, itis contemplated that the chassis 34 can be liquid impermeable. It isfurther contemplated that the chassis 34 can be vapor impermeable orvapor permeable (i.e., “breathable”). One suitable “breathable” materialis composed of a microporous polymer film or a nonwoven fabric that hasbeen coated or otherwise treated to impart a desired level of liquidimpermeability.

It is also contemplated that the chassis 34 may be stretchable, and moresuitably elastic. In particular, the chassis 34 is suitably stretchableand more suitably elastic in at least the transverse, or circumferentialdirection of the pant 20. In other embodiments, the chassis 34 may bestretchable, and more suitably elastic, in both the transverse and thelongitudinal direction. It is contemplated that the chassis 34 can bestretchable in any suitable direction.

As seen in FIG. 1, the training pant 20 includes an elasticizedwaistband system, indicated generally at 21, configured to fullyencircle the waist of the wearer during use. Referring now to FIGS. 1-3,the elasticized waistband system 21 of the illustrated embodimentincludes a bodyside front waist elastic member 94, a bodyside rear waistelastic member 96, a garment-side front waist elastic member 98, and agarment-side rear waist elastic member 100. The waist elastic members94, 96, 98, 100 can be formed of any suitable elastic material.Exemplary suitable elastic materials include sheets, strands or ribbonsof natural rubber, synthetic rubber, or thermoplastic elastomericpolymers. The elastic materials can be stretched and adhered to asubstrate, adhered to a gathered substrate, or adhered to a substrateand then elasticized or shrunk, for example with the application ofheat, such that elastic retractive forces are imparted to the substrate.

In one suitable embodiment, for example, the waist elastic members 94,96, 98, 100 comprise a plurality of dry-spun coalesced multifilamentspandex elastomeric threads sold under the trade name LYCRA® andavailable from Invista of Wichita, Kans., U.S.A. In another suitableembodiment, the waist elastic members 94, 96, 98, 100 comprise avertical filament laminate (VFL) material. A VFL is a composite materialhaving at least one gatherable layer such as a non-woven material and atleast one elastic layer. One type of vertical filament laminate isdisclosed, for example, by U.S. Pat. No. 6,916,750 to Thomas et al.,which is incorporated herein by reference. In another suitableembodiment, the waist elastic members 94, 96, 98, 100 comprise anelastic nonwoven composite having an apertured elastic film laminated toone or more nonwoven web materials, examples of which are described inU.S. Pat. No. 7,803,244 issued Sep. 28, 2010 to Siqueira et al., andU.S. Pat. No. 8,361,913 issued Jan. 29, 2013 to Siqueira et al., both ofwhich are incorporated herein by reference. Other suitable elasticmaterials include single- and dual-faced spandex laminates,stretch-bonded laminates (SBL), and continuous filament stretch-bondedlaminates (CFSBL), examples of which are described in U.S. Pat. No.5,385,775 issued Jan. 31, 1995 to Wright; U.S. Pat. No. 6,057,024 issuedMay 2, 2000 to Mleziva et al.; and U.S. Pat. No. 6,969,441 issued Nov.29, 2005 to Welch et al., all of which are incorporated herein byreference.

Although the elasticized waistband system 21 is illustrated anddescribed as including bodyside front and rear waist elastic members 94,96 and garment-side front and rear waist elastic members 98, 100, it isunderstood that in alternative embodiments the elasticized waistbandsystem 21 may include any combination of the bodyside front waistelastic member 94, the bodyside rear waist elastic member 96, thegarment-side front waist elastic member 98, and/or the garment-side rearwaist elastic member 100. In the illustrated embodiment, each elasticmember 94, 96, 98, 100 is generally rectangular in shape. Although thewaist elastic members 94, 96, 98, 100 are illustrated and described asbeing generally rectangular, it is understood that the waist elasticmembers may have any suitable shape. In one embodiment, for example, thegarment-side waist elastic members 98, 100 include undulated and/orscalloped edges.

As seen in FIGS. 2 and 3, the top edges of the front waist elasticmembers 94, 98 of the illustrated embodiment are generally aligned withthe front waist edge 30 of the training pant 20, and the top edges ofthe rear waist elastic members 96, 100 of the illustrated embodiment aregenerally aligned with the back waist edge 32 of the training pant 20.It is understood, however, that the top edges of one or more of thewaist elastic members 94, 96, 98, 100 can be spaced from the front waistedge 30 and/or the back waist edge 32. That is, the top edges of thefront waist elastic members 94, 98 can be spaced either above or belowthe front waist edge 30 of the training pant 20, and/or the rear waistelastic members 96, 100 can be spaced either above or below the backwaist edge 32 of the training pant 20. In one suitable embodiment, forexample, the bodyside front waist elastic member 94 and the garment-sidefront waist elastic member 98 extend beyond the front waist edge 30, andthe bodyside front waist elastic member 94 and the garment-side frontwaist elastic member 98 are bonded to one another such that the chassis34 is not visible along the front waist edge 30. Additionally oralternatively, the body-side rear waist elastic member 96 and thegarment-side rear waist elastic member 100 extend beyond the back waistedge 32, and the body-side rear waist elastic member 96 and thegarment-side rear waist elastic member 100 are bonded to one anothersuch that the chassis 34 is not visible along the back waist edge 32.

In the illustrated embodiment, the top edges of the bodyside waistelastic members 94, 96 are substantially aligned with the top edges of acorresponding garment-side waist elastic member 98, 100. Further, theside edges of the bodyside waist elastic members 94, 96 aresubstantially aligned with the side edges of a correspondinggarment-side waist elastic member 98, 100. As a result, thecorresponding bodyside and garment side waist elastic members 94, 96,98, 100 have a unitary appearance similar to that of waistbands employedin reusable underwear. Further, because the bodyside waist elasticmembers 94, 96 are at least partially aligned with the garment-sidewaist elastic members 98, 100, the elasticized waistband system 21 hasan increased thickness where the bodyside waist elastic members 94, 96are aligned with the garment-side waist elastic members 98, 100. Such anincreased thickness facilitates gripping and donning the training pant20, particularly for infants or toddlers whose motor skills are notfully developed. In one suitable embodiment, for example, the thicknessof the training pant 20 along the elasticized waistband system isbetween about 1.0 millimeters and about 6.0 millimeters and, moresuitably, between about 2.0 millimeters and about 5.0 millimeters.

As illustrated in FIGS. 2 and 3, each of the side edges of the front andrear waist elastic members 94, 96, 98, 100 are generally aligned withthe side edges 28 of training pant 20. Each of the front and rear waistelastic members 94, 96, 98, 100 extend from one side edge 28 of thetraining pant 20 to the other, laterally opposing side edge 28 of thetraining pant 20. The waist elastic members 94, 96, 98, 100 of theillustrated embodiment are configured to fully encircle the waistopening 66 (FIG. 1) and the wearer when the training pant 20 is donnedin the wearing configuration. It is understood, however, that the sideedges of one or more of the waist elastic members 94, 96, 98, 100 can bedisposed either outward or inward of the side edges 28 of the trainingpant.

As illustrated in FIGS. 2 and 3, each waist elastic member 94, 96, 98,100 has substantially the same length and width. It is understood,however, that the length and/or width of one or more of the waistelastic members 94, 96, 98, 100 may be different from the length and/orthe width of the other waist elastic members. In one suitableembodiment, for example, each of the garment-side waist elastic members98, 100 has a width greater than a width of the bodyside waist elasticmembers 94, 96.

The waist elastic members 94, 96, 98, 100 can be formed of any suitableelastic material including, for example, sheets, strands or ribbons ofnatural rubber, synthetic rubber, or thermoplastic elastomeric polymers.In one suitable embodiment, each waist elastic member 94, 96, 98, 100 isformed from the same material or materials as the other waist elasticmembers such that each waist elastic member has substantially the sameproperties (e.g., elasticity profile, coefficient of friction, softness,etc.) as the other waist elastic members. It is understood, however,that one or more waist elastic members 94, 96, 98, 100 may be formed ofdifferent materials to impart desired physical or visual properties tothe waist elastic member. In one suitable embodiment, for example, thebodyside waist elastic members 94, 96 have a coefficient of frictiongreater than a coefficient of friction of the garment-side waist elasticmembers 98, 100 to facilitate maintaining the position of the trainingpant 20 on the wearer, and reduce friction between the training pant andgarment(s) worn over the training pant.

The bodyside waist elastic members 94, 96 are attached to thebody-facing side 23 of the training pant 20 (FIG. 3), and thegarment-side waist elastic members 98, 100 are attached to thegarment-facing side 26 of the training pant 20 (FIG. 2). In theillustrated embodiment, for example, the waist elastic members 94, 96,98, 100 are point bonded to the chassis 34. In embodiments in which theabsorbent assembly 36 is interposed between the chassis 34 and thebodyside waist elastic members 94, 96, such as the embodimentillustrated in FIGS. 1-3, the bodyside waist elastic members may also bepoint bonded to the absorbent assembly 36, such as to the bodyside liner48 of the absorbent assembly 36. Alternatively, the bodyside waistelastic members 94, 96 may only be bonded to the training pant 20 alongthe chassis 34. In one suitable embodiment, for example, the bodysidewaist elastic members 94, 96 are bonded to a body-facing side of thechassis 34, and are interposed between the absorbent assembly 36 and thechassis 34. In another suitable embodiment, the front and back ends ofthe absorbent assembly 36 are spaced inward from the bottom edges of thebodyside waist elastic members 94, 96, and the bodyside waist elasticmembers 94, 96 are bonded to the body-facing side of the chassis 34.

In the illustrated embodiment and as seen in FIGS. 1 and 2, leg elasticmembers 82 are disposed on the garment-facing side 25 of the chassis 34.It is contemplated that the leg elastic members 82 can be disposed onthe body-facing side 23 of the chassis 34 in addition to or instead ofthe leg elastic members disposed on the garment-facing side 25. That is,in one suitable embodiment, the leg elastic members 82 can be disposedon both the body-facing and garment-facing sides 23, 25 of the chassis34. In another suitable embodiment, the leg elastic members 82 can bedisposed on either the body-facing side 23 or the garment-facing side 25of the chassis 34.

As seen in FIG. 2, each of the leg elastic members 82 includes aplurality of elastic elements (e.g., elastic strands 83) and a carriersheet 84 to facilitate attachment of the elastic elements to thetraining pant 20. It is contemplated, however, that the carrier sheet 84can be omitted in some embodiments, and the elastic strands 83 can beattached directly to the training pant 20 (e.g., the chassis 34).Although the leg elastic members 82 are illustrated as having threeelastic strands 83, the leg elastic strands may include any suitablenumber of elastic elements.

In the illustrated embodiment, the leg elastic members 82 are attached(e.g., bonded) to the garment-facing side 25 of the chassis 34 andpositioned generally in the crotch region 26 of the absorbent trainingpant 20. As illustrated in FIG. 2, the leg elastic members 82 arealigned with the respective side edge 28 of the training pant 20. Morespecifically, each of the illustrated leg elastic members 82 iscoterminous with the respective side edge 28. It is understood, however,that the leg elastic members 82 can have any suitable arrangement. Theleg elastic members 82 can be formed from any suitable elastic material,such as, for example, the elastic materials described above as beingsuitable for the waist elastic members 94, 96, 98, 100.

Referring now to FIG. 3, the absorbent assembly 36 of the illustratedembodiment is attached to the chassis 34 along at least the crotchregion 26 of the absorbent training pant 20 by an adhesive, ultrasonicbonds, thermal bonds, pressure bonds, or the like. Suitable adhesivescan be applied continuously or intermittently as beads, a spray,parallel swirls, or the like. Suitable ultrasonic bonds, pressure bonds,and/or thermal bonds can be formed continuously or intermittently alongthe absorbent assembly 36 to effect the attachment of the absorbentassembly 36 to the chassis 34. In the illustrated embodiment, theabsorbent assembly 36 is permanently attached to the chassis 34. Theterm “permanently attached” is synonymous with terms such as“permanently joined,” “permanently adhered,” and “permanently bonded,”and is intended herein to refer to an attachment that is generally notreleasable without some damage or substantially reduced functionality ofthe components that are permanently attached. In another suitableembodiment, the absorbent assembly 36 can be releasably attached to thechassis 34 by refastenable fasteners suitable for absorbent articles,such as adhesive fasteners, cohesive fasteners, mechanical fasteners(e.g., interlocking geometric shaped materials, such as hooks, loops,bulbs, mushrooms, arrowheads, balls on stems, male and female matingcomponents, buckles, snaps) or the like.

While the absorbent assembly 36 illustrated in FIG. 3 is shown anddescribed herein as being attached to the chassis 34 along the crotchregion 26, it is contemplated that the absorbent assembly 36 may beattached to the chassis 34 along any one or more of the crotch region26, the front waist region 22, and/or the back waist region 24, withoutdeparting from the scope of this disclosure. Further, the absorbentassembly 36 may be attached to the chassis 34 along any suitable lengthand/or area of the chassis 34.

As seen in FIG. 3, the illustrated absorbent assembly 36 is generallyrectangular in shape, although it is contemplated that the absorbentassembly 36 may have other suitable shapes without departing from thescope of the present disclosure. In the illustrated embodiment, thefront and back ends of the absorbent assembly 36 define respectiveportions of the front and back waist edges 30, 32 of the training pant20. It is contemplated, however, that the front end and/or back end ofthe absorbent assembly 36 can be spaced inward from the front and backwaist edges 30, 32 of the training pant 20. In such an embodiment, thefront and back waist edges 30, 32 of the training pant 20 are definedsolely by the chassis 34. As illustrated in FIG. 3, the side edges ofthe absorbent assembly 36 can be spaced slightly inward from the sideedges 28 of the absorbent training pant 20. In other suitableembodiments, the opposite side edges of the absorbent assembly 36 canform portions of the side edges 28 of the absorbent training pant 20.

In one suitable embodiment and as illustrated in FIG. 3, the absorbentassembly 36 comprises a liquid impermeable backsheet 46 and a bodysideliner 48 attached to the backsheet in a superposed relation by suitablemeans such as adhesives, ultrasonic bonds, pressure bonds, thermal bondsor other conventional techniques. An absorbent structure (or absorbentcore) 50 is disposed between the backsheet 46 and the bodyside liner 48.A pair of containment flaps 52 is integrally formed from the absorbentassembly 36 for inhibiting the lateral flow of body exudates.

In one suitable embodiment, the backsheet comprises a material which issubstantially liquid impermeable. The backsheet 46 can be a single layerof liquid impermeable material, or may comprise a multi-layered laminatestructure in which at least one of the layers is liquid impermeable.Multiple layers of the backsheet 46 may be suitably joined together byan adhesive, ultrasonic bonds, pressure bonds, thermal bonds, or thelike. Suitable adhesives can be applied continuously or intermittentlyas beads, a spray, parallel swirls, or the like.

The backsheet 46 can be both liquid and vapor impermeable, or, moresuitably, it may be liquid impermeable and vapor permeable. Thebacksheet 46 can be manufactured from a thin plastic film, althoughother flexible liquid impermeable materials may also be used. Thebacksheet 46 prevents waste material from wetting articles, such as bedsheets and clothing, as well as the wearer and caregiver. In onesuitable embodiment, the liquid impermeable material can permit vaporsto escape from the interior of the disposable absorbent article, whilestill preventing liquids from passing through the backsheet 46. Onesuitable “breathable” material is composed of a microporous polymer filmor a nonwoven fabric that has been coated or otherwise treated to imparta desired level of liquid impermeability.

It is also contemplated that the backsheet 46 may comprise a liquidpermeable material, or the backsheet 46 may be omitted from theabsorbent assembly 36 altogether. In such embodiments, the chassis 34suitably comprises a liquid impermeable material to provide a liquidbarrier to body exudates. In one embodiment in which the backsheet 46 isomitted, the bodyside liner 48 is attached to the chassis 34 such thatthe absorbent structure 50 is disposed between the bodyside liner 48 andthe inner surface of the chassis 34. In another suitable embodiment,both the absorbent structure 50 and the bodyside liner 48 are attachedto the chassis 34.

It is also contemplated that the backsheet 46 may be stretchable, andmore suitably elastic. In particular, the backsheet 46 is suitablystretchable and more suitably elastic in at least the transverse, orcircumferential direction of the pant 20. In other embodiments thebacksheet 46 may be stretchable, and more suitably elastic, in both thetransverse and the longitudinal direction.

The bodyside liner 48 is suitably compliant, soft-feeling, andnon-irritating to the wearer's skin. The bodyside liner 48 is alsosufficiently liquid permeable to permit liquid body exudates to readilypenetrate through its thickness to the absorbent structure 50. Further,the bodyside liner 48 can be less hydrophilic than the absorbentstructure 50 to present a relatively dry surface to the wearer andpermit liquid to readily penetrate through its thickness. Thehydrophilic/hydrophobic properties can be varied across the length,width and/or depth of the bodyside liner 48 and absorbent structure 50to achieve the desired rate of fluid intake and dryness.

A suitable bodyside liner 48 may be manufactured from a wide selectionof web materials, such as porous foams, reticulated foams, aperturedplastic films, woven and non-woven webs, or a combination of any suchmaterials. For example, the bodyside liner 48 may comprise a meltblownweb, a spunbonded web, or a bonded-carded-web composed of naturalfibers, synthetic fibers or combinations thereof. The bodyside liner 48may be composed of a substantially hydrophobic material, and thehydrophobic material may optionally be treated with a surfactant orotherwise processed to impart a desired level of wettability andhydrophilicity. The surfactant can be applied by any conventional means,such as spraying, printing, brush coating or the like. The surfactantcan be applied to the entire bodyside liner 48 or can be selectivelyapplied to particular sections of the bodyside liner, such as the medialsection along the longitudinal center line.

The bodyside liner 48 may also be stretchable, and more suitably it maybe elastomeric. Suitable elastomeric materials for construction of thebodyside liner 48 can include elastic strands, LYCRA elastics, cast orblown elastic films, nonwoven elastic webs, meltblown or spunbondelastomeric fibrous webs, as well as combinations thereof. Examples ofsuitable elastomeric materials include KRATON elastomers, HYTRELelastomers, ESTANE elastomeric polyurethanes (available from Noveon ofCleveland, Ohio), or PEBAX elastomers. The bodyside liner 48 can also bemade from extensible materials as are described in U.S. patentapplication Ser. No. 09/563,417 filed on May 3, 2000 by Roessler et al.or from biaxially stretchable materials as are described in U.S. patentapplication Ser. No. 09/698,512 filed on Oct. 27, 2000 by Vukos et al.,both references which are hereby incorporated by reference.

As seen in FIG. 3, the illustrated absorbent structure 50 is generallyrectangular. It is contemplated, however, that the absorbent structure50 can have any suitable shape and size. For example, the absorbentstructure 50 can include arcuate leg cutouts (e.g., by die cutting theabsorbent structure) in the crotch region 26 of the training pant 20.While the illustrated absorbent structure 50 is shown and describedherein as extending from the crotch region 26 into both the front andback waist regions 22 and 24, it is contemplated that the absorbentstructure may extend from the crotch region 26 into only the front waistregion 22, or only the back waist region 24, without departing from thescope of this disclosure.

The absorbent structure 50 is suitably compressible, conformable,non-irritating to a wearer's skin, and capable of absorbing andretaining liquids and certain body wastes. For example, the absorbentstructure 50 may comprise cellulosic fibers (e.g., wood pulp fibers),other natural fibers, synthetic fibers, woven or nonwoven sheets, scrimnetting or other stabilizing structures, superabsorbent material, bindermaterials, surfactants, selected hydrophobic materials, pigments,lotions, odor control agents or the like, as well as combinationsthereof. In a particular embodiment, the absorbent structure comprises amatrix of cellulosic fluff and superabsorbent hydrogel-formingparticles. The cellulosic fluff may include a blend of wood pulp fluff.Suitable types of fluff include, for example, fluff pulp commerciallyavailable from Weyerhaeuser Company under the designation FR416 (7.5percent Moisture) and CF416 (7.5 percent Moisture). Weyerhaeuser Companyhas offices in Federal Way, Wash., U.S.A.

The materials may be formed into a web structure by employing variousconventional methods and techniques. For example, the absorbentstructure 50 may be formed by a dry-forming technique, an air formingtechnique, a wet-forming technique, a foam-forming technique, or thelike, as well as combinations thereof. Methods and apparatus forcarrying out such techniques are well known in the art. Furthermore, theabsorbent structure 50 may itself encompass multiple layers in aZ-direction (e.g., thickness) of the absorbent structure 50. Suchmultiple layers may take advantage of differences in absorbent capacity,such as by placing a lower absorbent capacity material layer closer tothe liner 48 and a higher absorbent capacity material closer to thebacksheet 46. Likewise, discrete portions of a single-layered absorbentstructure may encompass higher capacity absorbents, and other discreteportions of the structure may encompass lower capacity absorbents.

Superabsorbent material is suitably present in the absorbent structure50 in an amount of from about 0 to about 100 weight percent based ontotal weight of the absorbent structure 50. The absorbent structure 50may suitably have a density within the range of about 0.10 to about 0.60grams per cubic centimeter. Superabsorbent materials are well known inthe art and can be selected from natural, synthetic, and modifiednatural polymers and materials. The superabsorbent materials can beinorganic materials, such as silica gels, or organic compounds, such ascrosslinked polymers. Typically, a superabsorbent material is capable ofabsorbing at least about 10 times its weight in liquid, and preferablyis capable of absorbing more than about 25 times its weight in liquid.Suitable superabsorbent materials are readily available from varioussuppliers. For example, Hysorb T 9700 superabsorbent, which iscommercially available from BASF of Ludwigshafen, Germany, or Favor SXM5600 superabsorbent, which is commercially available from Evonik ofEssen, Germany.

The absorbent structure 50 may alternatively comprise a coform material.The term “coform material” generally refers to composite materialscomprising a mixture or stabilized matrix of thermoplastic fibers and asecond non-thermoplastic material. As an example, coform materials aremade by a process in which at least one meltblown die head is arrangednear a chute through which other materials are added to the web while itis forming. Such other materials may include, but are not limited to,fibrous organic materials such as woody or non-woody pulp such ascotton, rayon, recycled paper, pulp fluff and also superabsorbentparticles, inorganic absorbent materials, treated polymeric staplefibers and the like. Any of a variety of synthetic polymers may beutilized as the melt-spun component of the coform material. Forinstance, in certain aspects, thermoplastic polymers can be utilized.Some examples of suitable thermoplastics that can be utilized includepolyolefins, such as polyethylene, polypropylene, polybutylene and thelike; polyamides; and polyesters. In one aspect, the thermoplasticpolymer is polypropylene. Some examples of such coform materials aredisclosed in U.S. Pat. Nos. 4,100,324 to Anderson, et al.; 5,284,703 toEverhart, et al.; and 5,350,624 to Georger, et al.; which areincorporated herein by reference.

In one suitable embodiment, the absorbent structure 50 is stretchable soas not to inhibit the stretchability of other components to which theabsorbent structure may be adhered, such as the backsheet 46 andbodyside liner 48. After being formed or cut to a desired shape, theabsorbent structure 50 may be wrapped or encompassed by a suitable wrap(not shown) that aids in maintaining the integrity and shape of theabsorbent structure.

The absorbent assembly 36 is configured to contain and/or absorbexudates discharged from the wearer. For example, the containment flaps52 are configured to provide a barrier to the transverse flow of bodyexudates. A flap elastic member 72 (FIG. 3) may be operatively joinedwith each containment flap 52. The elasticized containment flaps 52define a partially unattached, or free, edge which assumes an uprightconfiguration in at least the crotch region 26 of the absorbent trainingpant 20 to form a seal against the wearer's body during use. In onesuitable embodiment, the containment flaps 52 can be located along theside edges 28 of the training pant 20, and can extend longitudinallyalong the entire length of the absorbent assembly 36 or may only extendpartially along the length of the absorbent assembly 36.

In the illustrated embodiment, the absorbent assembly 36 also includes asurge management layer 76, which can be seen in FIG. 3, located adjacentthe absorbent structure 50 (e.g., between the absorbent structure 50 andthe liner 48). The surge management layer 76 helps to decelerate anddiffuse surges or gushes of liquid that may be rapidly introduced intothe absorbent structure 50 of the training pant 20 by the wearer.Desirably, the surge management layer 76 can rapidly accept andtemporarily hold the liquid prior to releasing the liquid into thestorage or retention portions of the absorbent structure 50. Examples ofsuitable surge management layers are described in U.S. Pat. No.5,486,166 issued Jan. 23, 1996 to Bishop et al.; U.S. Pat. No. 5,490,846issued Feb. 13, 1996 to Ellis et al.; and U.S. Pat. No. 5,820,973 issuedOct. 13, 1998 to Dodge, II et al., the entire disclosures of which arehereby incorporated by reference herein.

Referring again to FIG. 1, the training pant 20 includes a pair ofnon-refastenable fin seams 70. One of the fin seams 70 is disposed onone side of the training pant 20 and the other fin seam is disposed onthe opposite side of the pant. It is understood, however, that the finseams 70 can be located at any suitable location on the training pant 20and that the seams can be formed using any suitable bonding method suchas, e.g., adhesive bonding, thermal bonding, pressure bonding, andcombinations thereof. In one suitable bonding method, which is describedin more detail below, the fin seams 70 can be formed using ultrasonicbonding.

As seen in FIG. 1, the front and back waist regions 22, 24 are attachedto each other by the fin seams 70 to define a wear configuration of thepant having the waist opening 66 and a pair of leg openings 68. Thewaist edges 30, 32 of the absorbent training pant 20 are configured toencircle the waist of the wearer and together define the waist opening66, and portions of the side edges 28 in the crotch region 26 generallydefine the leg openings 68. Each of the fin seams 70 extends at leastpart of the way from the waist opening 66 to the respective leg opening68. In the illustrated embodiment, for example, each of the fin seams 70extends approximately the entire distance between the waist opening 66and the respective leg opening 68. It is contemplated, however, that insome suitable embodiments, the fin seams 70 can extend a distance lessthan the entire distance between the waist opening 66 and the respectiveleg opening 68.

FIG. 4 is an enlarged fragmentary view taken from one of the fin seams70 of FIG. 1. In the illustrated embodiment, the fin seams 70 are formedby point bonding the front waist region 22 of the training pant 20 tothe back waist region 24 along the side edges 28 such that thebody-facing surface 23 of the chassis 34 in the front waist region isbonded in face-to-face relationship with the body-facing surface of thechassis in the back waist region. As seen in FIG. 4, the illustrated finseam 70 extends outward from the training pant 20. Thus when thetraining pant 20 is donned, the fin seams 70 extend away from thewearer. It is contemplated, however, that the fin seams 70 can extendinward. In such an embodiment, the fin seams 70 would extend toward thewearer when the training pant 20 is donned.

In one suitable embodiment, each of the fin seams 70 has a width FW lessthan 5.0 mm, and more suitably less than 3 mm. Suitably, for example,each of the fin seams 70 has a width FW of about 1 mm. As seen in FIG.5, the width FW of the fin seams 70 is a measurement of how far the finseam extends outward from the training pant 20 in a direction generallyparallel to the transverse axis 62 of the pant.

With reference still to FIG. 4, the point bonding results in a pluralityof discrete point bonds 43. In one suitable embodiment, the point bonds43 are aligned in columns (FIG. 4). In the illustrated embodiment, forexample, the point bonds are aligned in two distinct columns: a firstcolumn C1 and a second column C2. It is understood, however, that thediscrete point bonds 43 can be arranged in any suitable number ofcolumns. That is, the point bonds 43 can be arranged in fewer columns(i.e., one) or more than the two columns illustrated in FIG. 4 withoutdeparting from some aspects of this disclosure. It is also understoodthat the point bonds can have any suitable arrangement without departingfrom some aspects of this disclosure.

As seen in FIG. 4, the point bonds 43 of one column are longitudinallyoffset relative to the point bonds in the adjacent column. As a result,the point bonds 43 are not aligned in transversely extending rows. Morespecifically, in the illustrated embodiment, the point bonds 43 of thefirst column C1 define a first longitudinal center line and the pointbonds of the second column C2 define a second longitudinal center line.In one suitable embodiment, an outer periphery or boundary of the pointbonds 43 defining the first column C1 are generally aligned with orextend beyond the centerline of the second column C2. Likewise, an outerperiphery or boundary of the point bonds 43 defining the second columnC2 are generally aligned with or extend beyond the centerline of thefirst column C1. Also in the illustrated embodiment, the outer peripheryor boundary of the point bonds 43 contact the outer periphery orboundary of the adjacent point bonds 43.

In the illustrated embodiment and as best seen in FIGS. 5-7, the pointbonds 43 form generally domed-shaped recesses but it is understood thatthe point bonds 43 can form any suitable shape or relative arrangement.In one suitable embodiment, each of the point bonds 43 is generally thesame size and shape. It is understood, however, that the size and shapeof point bonds 43 can differ. That is, the point bonds 43 forming thefin seam 70 can vary in size and/or shape. Suitably, however, all of thepoint bonds 43 forming the fin seam 70 are of the same size and shape asillustrated in FIG. 4.

In one suitable embodiment, each of the point bonds 43 has a diameter(or more broadly a greatest extent) between about 0.5 mm and about 2 mm.Suitably, for example, the diameter of each of the point bonds 43 isabout 1.5 mm. As explained above, the point bonds 43 of the two columnsC1, C2 overlap. In one suitable embodiment, the point bonds 43 of theadjacent columns C1, C2 overlap by about half the diameter of the pointbonds. For example, in an embodiment having point bonds 43 with adiameter of 1.5 mm, the point bonds of one of the columns C1, C2 willoverlap the point bonds of the other column by about 0.75 mm.

FIGS. 5-7 are cross-sections taken through various locations of the finseam 70 of FIG. 4. Specifically, FIG. 5 is a cross-section taken throughthe fin seam 70 formed in the elasticized waistband system 21. Asillustrated therein, the point bonds 43 are formed through the bodysidefront waist elastic member 94, the bodyside rear waist elastic member96, the garment-side front waist elastic member 98, the garment-siderear waist elastic member 100 and the underlying chassis 34. FIG. 7 is across-section taken through the fin seam 70 formed through therespective leg elastic member 82. As seen in FIG. 7, the point bonds 43are formed through the leg elastic member 82 and the underlying chassis.FIG. 6 is a cross-section taken through the fin seam 70 at a locationbetween the waistband system 21 and the leg elastic member 82. Asillustrated in FIG. 6, the point bonds 43 are formed through the chassis34.

In one suitable embodiment, the point bonds 43 formed through thewaistband system 21, the leg elastic member 82 and the portion of thechassis 34 located between the waistband system and the leg elasticmember are substantially the same. That is, the point bonds 43throughout the length of the fin seam 70 have substantially the samesize and shape and are applied in the same pattern and at the samedensity. In another suitable embodiment, the point bonds 43 formed alongthe length of the fin seam 70 can differ in size or shape or be appliedin different patterns or at different densities. For example, the pointbonds 43 formed through the waistband system 21 can differ from thepoint bonds formed through the leg elastic member 82 and/or the portionof the chassis 34 located between the waistband system and the legelastic member. In another example, the point bonds 43 formed throughthe leg elastic members 82 can differ from the point bonds formedthrough the waistband system 21 and/or the portion of the chassis 34located between the waistband system and the leg elastic member.

A plurality of the training pants 20 illustrated in FIGS. 1-7 can bemanufactured using any suitable manufacturing method. In one suitablemethod of manufacturing, each training pant 20 of the plurality of thetraining pant is folded at a suitable folding station. Morespecifically, each of the training pants 20 are folded about a fold linegenerally bisecting the training pant (i.e., folded about the transverseaxis 62. As such, the front and back waist regions 22, 24 of eachtraining pant 20 are positioned in facing relationship. Morespecifically, the bodyfacing surface 23 of front region 22 of thechassis is positioned in face-to-face relationship with the bodyfacingsurface of the back region 24 as illustrated in FIG. 8.

Once the training pant 20 is folded, the fin seams 70 can be formed at abonding and slitting station, indicated generally at 200 in FIG. 8. Asseen in FIG. 8, the illustrated bonding station 200 comprises a firstbonding and slitting device 202 and a second bonding and slitting device204. The first bonding and slitting device 202 is configured to form thefin seam 70 on one of the sides (i.e., along one of the side edges 28)of the training pant 20, and the second bonding and slitting device 204is configured to form the fin seam on the opposite side (i.e., along theother side edge).

In the illustrated embodiment, the first bonding and slitting device 202is independent of the second bonding and slitting device 204. That is,the first bonding and slitting device 202 can be operated independentlyof the second bonding and slitting device 204. In another suitableembodiment, the first and second bonding and slitting devices 202, 204can be dependent on each other. In one such embodiment, for example, thefirst bonding and slitting device 202 and the second bonding andslitting device 204 can be formed on a single roll in spacedrelationship with each other.

In one suitable embodiment and as illustrated in FIG. 8, both the firstand second bonding and slitting devices 202, 204 are substantially thesame and comprise suitable bonding devices. It is understood that anysuitable bonding device can be used without departing from some aspectsof this disclosure. Each of the first and second bonding and slittingdevices 202, 204 comprise a first bonding member and a seconding membercapable of bonding the fin seam 70. More specifically in the illustratedembodiment, the first and second bonding and slitting devices 202, 204each comprise a rotary ultrasonic horn 208 (broadly, the first bondingmember) and a cooperating rotary anvil 210 (broadly, the second bondingmember) adapted to ultrasonically bond and, more specifically, pointbond the front region 22 of the chassis 34 to the back region 24 todefine the fin seams 70 and to trim, score, perforate or otherwiseweaken the material outboard of the point bonds from both the front andback regions of the chassis. The horn 208 and anvil 210 cooperativelydefine, at least in part, the ultrasonic bonding device. Suitable rotaryultrasonic horns are available from Aurizon Ultrasonics, LLC ofKimberly, Wis., U.S.A.

Since the first and second bonding and slitting devices 202, 204 are thesame, the operation of only the first bonding and slitting device 202 isdescripted herein with the understanding that the second bonding andslitting device 204 operates in the same manner. With reference now toFIGS. 9 and 11, which illustrates the operation of the first bonding andslitting device 202, the ultrasonic horn 208 and anvil 210 areconfigured to counter-rotate with respect to each other. That is, theultrasonic horn 208 rotates in one direction and the anvil rotates inthe opposite direction. In the illustrated embodiment, for example, theultrasonic horn 208 rotates in a clockwise direction and the anvil 210rotates in a counterclockwise direction.

A suitable horn drive (not shown) can be operatively connected to theultrasonic horn 208 to rotate the ultrasonic horn, and a suitable anvildrive (not shown) can be operatively connected to the anvil 210 torotate the anvil. The horn drive and anvil drive may be separate drivingmechanisms, or may be the same driving mechanism. In one suitableembodiment, the horn 208 may be rotated by a driving mechanism, and theanvil member may be driven by the contact pressure between the horn, thetraining pant 20 and the anvil 210. Suitable driving mechanism caninclude, for example, take-offs from a powered line shaft, motors,engines, electric motors or the like, as well as combinations thereof.

As seen in FIGS. 9 and 11, the illustrated ultrasonic horn 208 is acircular cylinder having an outer peripheral surface 288. It isunderstood, however, that the ultrasonic horn 208 can have any suitableshape and/or configuration. In one suitable embodiment, the ultrasonichorn 208 can be rotated by its corresponding drive to provide an outerperipheral speed at its outer peripheral surface 288. Suitably, theouter peripheral speed of the ultrasonic horn 208 can be between about100 m/min and about 600 m/min, and more suitably between about 200 m/minand about 400 m/min. For example, in one suitable embodiment, the outerperipheral speed of the ultrasonic horn 208 is about 300 m/min. It isunderstood, however, the ultrasonic horn 208 can operate at any suitableouter peripheral speed without departed from some aspects of thisinvention. It is further understood that the outer peripheral speed maybe substantially constant, or may be non-constant (i.e., variable) asdesired.

In one suitable embodiment, the rotatable anvil 210 can be rotated byits corresponding drive to provide a desired anvil speed at its outerperipheral surface. Suitably, the outer peripheral speed of the anvil210 can be between about 100 m/min and about 600 m/min, and moresuitably between about 200 m/min and about 400 m/min. For example, inone suitable embodiment, the outer peripheral speed of the anvil 210 isabout 300 m/min. It is understood, however, the anvil 210 can operate atany suitable outer peripheral speed without departed from some aspectsof this invention. It is further understood that the outer peripheralspeed may be substantially constant, or may be non-constant (i.e.,variable) as desired.

With reference still to FIGS. 9 and 11, the illustrated anvil 210comprises an outer disk 212, an inner disk 214, and a contact element216 disposed between the outer and inner disks. In the illustratedembodiment, the contact element 216 is spaced from the inner and outerdisks by a pair of annular recesses 218. It is contemplated that theanvil 210 can have any suitable configuration without departing fromsome aspects of this disclosure.

The contact element 216 is configured to cooperate with the horn 208 toultrasonically point bond the front region 22 of the chassis 34 to theback region 24 to define the fin seams 70 and to trim or otherwise acton material outboard of the point bonds from both the front and backregions of the chassis. More specifically and as illustrated in FIG.10A, which is an enlargement of a portion of the contact element 216 ofFIG. 9, the contact element has an engagement surface 220 extendingabout the circumference of the contact element 216 having a plurality ofbonding elements 222 adapted to point bond the front region 22 and theback region 24 of the chassis 34, and a slitter 224 adapted to cut boththe front region 22 and the back region 24. It is contemplated, however,that the slitter 224 can be adapted to weaken (score, perforate) ratherthan cut one of or both the front region 22 and the back region 24 ofthe chassis 34 to facilitate later removal of material outboard of thepoint bonds 43.

The bonding elements 222 of the contact element 216 can have anysuitable configuration (including, e.g., size, shape, spacing) toachieve the desired bond pattern. In the illustrated embodiment, thebonding elements 222 encircle the full circumference of the contactelement 216. In other words, the bonding elements 222 are providedcontinuously over the entire circumferential distance of the contactelement 216. It is contemplated, however, that the bonding elements 222can extend over only a portion or discrete portions of the circumferenceof the contact element 216. It is also contemplated that bondingelements 222 can be provided on ultrasonic horn 288 in addition to orinstead of the bonding elements on the contact element 216 of the anvil210.

In the illustrated embodiment, the bonding elements 222 are configuredto achieve the plurality of discrete point bonds 43 illustrated in FIG.4. More specifically, the bonding elements 222 of FIG. 10A are alignedin two distinct columns. It is understood, however, that the bondingelements 222 can be aligned in any suitable number of columns. That is,the bonding elements 222 can be aligned in fewer columns (i.e., one) ormore than the two columns illustrated in FIG. 10A without departing fromsome aspects of this disclosure.

As seen in FIG. 10A, the bonding elements 222 of one column arelongitudinally offset relative to the bonding elements 222 in theadjacent column. As a result, the bonding elements 222 are not alignedin transversely extending rows. More specifically, in the illustratedembodiment, a circumferentially extending centerline CCL1 through onecolumn of bonding elements 222 is spaced from a circumferentiallyextending centerline CCL2 through the other column of bonding elements222 by a distance D1. While the distance D1 can be any suitabledistance, in one suitable embodiment the distance D1 is between about0.5 mm and about 2 mm, and more suitable between about 0.6 mm and about1 mm. For example, in the illustrated embodiment, the distance D1 isapproximately 1 mm.

In the illustrated embodiment, the bonding elements 222 are generallyfrustum nubs but it is understood that the bonding elements can have anysuitable shape or relative arrangement. In one suitable embodiment, eachof the bonding elements 222 has a maximum diameter (or more broadly agreatest extent) between about 0.5 mm and about 2 mm. Suitably, forexample, the diameter of each of the bonding elements 222 illustrated inFIG. 10A is about 1 mm. In another suitable embodiment, which isillustrated in FIG. 10B, the diameter of each of the bonding elements222 is about 1.5 mm. It is understood that the bonding elements 222 canhave any suitable diameter (or greatest extent).

In one suitable embodiment, the bonding elements 222 disposed on thecontact element 216 are all the same size and shape and are arranged inthe same pattern and at the same density about the entire circumferenceof the contact element. It is understood, however, that the bondingelements 222 can extend about only a portion of the circumference of thecontact element 216. It is further understood that the bonding elements222 disposed on the contact element 216 can vary in size, shape,pattern, and/or density about the circumference of the contact element216. In one such embodiment, the contact element 216 has a plurality ofzones of bonding elements 222 with each zone having at least one of adifferent size, shape, pattern, and/or density. Each of the zones ofbonding elements 222 can be phased (or registered) with a portion orportions of the fin seam 70. For example, one zone of bonding elements222 can be phased with the portion of the fin seam 70 comprising thewaistband system 21, another zone of bonding elements can be phased withthe portion of the fin seam comprising the leg elastic members 82, andyet another zone of bonding elements can be phased with the portion ofthe chassis 34 located between the waistband system 21 and the legelastic member 82.

As seen in FIGS. 9 and 11, the slitter 224 of the illustrated embodimentof the anvil 210, which is continuous about the circumference of thecontact element 216, is aligned with the outer edges of the outer mostcolumn of bonding elements 222. More specifically, in the illustratedembodiment, the slitter 224 contacts the outer edges of the outer mostcolumn of bonding elements 222. It is contemplated that in othersuitable embodiments, the slitter 224 can be slightly spaced from thebonding elements 222 such that the slitter is free from contact with thebonding elements. For example, in one suitable embodiment, the slitter224 can be spaced from the bonding elements 222 by a distance betweenabout 0.5 mm and about 5 mm.

The slitter 224 of the contact element 216 of the anvil 210 is adaptedto trim material 250 from both the front region 22 and the back region24 of the chassis 34 simultaneously as the bonding elements 222 arebonding the front and back regions (FIG. 9). Thus, the front region 22and the back region 24 of the chassis 34 are being cut and bonded at thesame time as the chassis passes through the first bonding and slittingdevice 202.

An ultrasonic exciter (not shown) is operatively connected to theultrasonic horn 208 to direct a sufficient amount of ultrasonic powerinto the horn through suitable, ultrasonic wave-guides, booster members,and connection/transmission components. In one suitable embodiment, forexample, the ultrasonic exciter is operatively connected to the horn208, and is capable of providing an operative amount of ultrasonicenergy at a frequency within the range of about 15-60 KHz (Kilo-Hertz).Suitable ultrasonic exciters, ultrasonic connectors, ultrasonic boostersand ultrasonic wave-guides are well known in the art and are availablefrom commercial vendors. Examples of suitable ultrasonic power systemsinclude, but are not limited to, a Model 20A3000 system available fromDukane Ultrasonics, which has offices located in St. Charles, Ill.; anda Model 2000CS system available from Herrmann Ultrasonics, which hasoffices located in Schaumburg, Illinois.

In operation, a plurality of folded training pants 20 are fed insuccession to the bonding and slitting station, indicated generally at200 in FIG. 8. In the illustrated embodiment, the training pants 20 arefed in the machine direction with crotch region 26 first but it isunderstood that the training pants can be fed to the bonding andslitting station 200 in any suitable manner including, for example, withthe crotch region 26 last or in a cross-machine direction.

At the bonding station 200, the first bonding and slitting device 202forms the fin seam 70 on one side (i.e., along one of the side edges 28)of the training pant 20, and the second bonding and slitting device 204forms the fin seam on the opposite side (i.e., along the other sideedge). More specifically, the training pants 20, which as mentionedabove are being fed crotch region 26 first in the illustratedembodiment, pass through the nip defined by the ultrasonic horn 208 andthe anvil 210 for each of the first and second bonding and slittingdevices 202, 204. The horn 208 of each of the devices 202, 204, which isultrasonically operating, cooperates with the respective anvil 210 topoint bond and trim the front and back waist regions 22, 24 of thechassis 34 adjacent the side edges 28.

As explained above, the contact element 216 of each anvil 210 isconfigured to cooperate with the respective horn 208 to ultrasonicallypoint bond via the bonding elements 222 the front region 22 of thechassis 34 to the back region 24 to define the fin seams 70 and to trimmaterial outboard of the point bonds from both the front and backregions of the chassis. The slitter 224 of the contact element 216 ofeach of the anvils 210 trims material 250 from both the front region 22and the back region 24 of the chassis 34 simultaneously as the bondingelements 222 bond the front and back regions to form the fin seams 70.Thus, the front region 22 and the back region 24 of the chassis 34 arecut and bonded at the same time as the chassis passes through the firstand second bonding and slitting devices 202, 204.

As the training pant 20 passes through the bonding station 200, theportion of the fin seam 70 extending through the respective leg elasticmember 82 is formed first. As seen in FIG. 7, the point bonds 43 formedby the bonding elements 222 are formed through the leg elastic member 82and the underlying chassis. Moreover, the slitter 224 trims materialfrom both the leg elastic member 82 and the underlying chassis 34 (i.e.,the front region 22 and the back region 24). As illustrated in FIG. 7,the material defining the side edge 28, which was trimmed by theslitter, has a first thickness.

FIG. 6 is a cross-section taken through the fin seam 70 at a locationbetween the waistband system 21 and the leg elastic member 82. Asillustrated in FIG. 6, the point bonds 43 are formed by the bondingelements 222 through the chassis 34. The slitter 224 trims material fromthe underlying chassis 34 (i.e., the front region 22 and the back region24). As illustrated in FIG. 6, the material defining the side edge 28,which was trimmed by the slitter, has a second thickness which issubstantially less than the first thickness.

FIG. 5 is a cross-section taken through the fin seam 70 at the waistbandsystem 21. The point bonds 43 are formed via the bonding elements 222through the bodyside front waist elastic member 94, the bodyside rearwaist elastic member 96, the garment-side front waist elastic member 98,the garment-side rear waist elastic member 100 and the underlyingchassis 34. The slitter 224 trims material from the waistband system 21and the underlying chassis 34 (i.e., the front region 22 and the backregion 24). As illustrated in FIG. 5, the material defining the sideedge 28, which was trimmed by the slitter, has a third thickness whichis significantly greater than both the first and second thicknesses.Thus, as the training pants 20 are fed through the bonding station 200,the ultrasonic horn 208 and anvil 210 have to accommodate for the threedifferent thicknesses of the fin seams 70.

When introducing elements of the present invention or the preferredembodiment(s) thereof, the articles “a”, “an”, “the”, and “said” areintended to mean that there are one or more of the elements. The terms“comprising,” “including”, and “having” are intended to be inclusive andmean that there may be additional elements other than the listedelements.

As various changes could be made in the above constructions withoutdeparting from the scope of the invention, it is intended that allmatter contained in the above description or shown in the accompanyingdrawings shall be interpreted as illustrative and not in a limitingsense.

What is claimed is:
 1. A bonding and slitting device adapted to form fin seams in absorbent articles having a front waist region, a back waist region, and a crotch region extending between the front waist region and the back waist region, the device comprising: a first bonding member; and a second bonding member having a contact element configured to cooperate with the first bonding member to bond the front region of the chassis to the back region to define the fin seams, and a slitter configured to simultaneously act on material outboard of the bonds from both the front and back regions of the chassis.
 2. The bonding and slitting device as set forth in claim 1 wherein the contact element includes a plurality of bonding elements adapted to point bond the front region and the back region of the chassis.
 3. The bonding and slitting device as set forth in claim 2 wherein the contact element has a circumference and the bonding elements extend continuously about the circumference of the contact element.
 4. The bonding and slitting device as set forth in claim 2 wherein the bonding elements are aligned in at least two circumferentially extending columns, each column being offset relative to an adjacent column.
 5. The bonding and slitting device as set forth in claim 4 wherein each of the columns of bonding elements define a circumferentially extending centerline, each centerline being spaced from an adjacent centerline by a distance between 0.5 mm and 2 mm.
 6. The bonding and slitting device as set forth in claim 2 wherein at least some of the bonding elements are frustum nubs.
 7. The bonding and slitting device as set forth in claim 2 wherein the slitter is spaced from the bonding elements by a distance between 0.5 mm and 5 mm.
 8. The bonding and slitting device as set forth in claim 1 wherein the contact element has a circumference and the slitter extends continuously about a circumference of the contact element.
 9. The bonding and slitting device as set forth in claim 1 wherein the first bonding member is a rotary ultrasonic horn and the second bonding member is a rotary anvil, the ultrasonic horn and the anvil being configured to counter-rotate with respect to each other. 